Sustainable Textile-Based Nonwoven Composites for Thermal and Acoustic Insulation: Materials, Methods, Performance, and Circular Pathways

Abstract

Background: Growing concerns about energy efficiency, resource depletion, and the environmental footprint of building and transport sectors have directed attention toward sustainable insulation solutions derived from textile-based materials and natural fibres. Textile-derived nonwovens, recycled fibres, and agricultural waste streams present promising raw-material sources that can simultaneously address acoustic and thermal performance requirements while aligning with circular-economy strategies.

Objective: This article synthesizes contemporary literature on textile-based composites and nonwoven materials for thermal and acoustic insulation, critically examines material selection and processing pathways, proposes detailed experimental and characterization methodologies that are consistent with current best practice, and integrates insights on circularity, energy sustainability, and techno-economic considerations to provide a comprehensive roadmap for academic and industrial stakeholders.

Methods: We present an integrative methodological framework describing material sourcing (recycled nonwovens, agricultural residues such as luffa, and natural fibre blends), nonwoven manufacturing and consolidation techniques (carding, needlepunching, hydroentangling, thermal bonding, and environmentally compatible binders), and performance characterization (thermal conductivity, heat capacity proxies, sound absorption coefficients across broad frequency bands, moisture sorption, durability, and fire performance proxies). We emphasize descriptive, reproducible protocols and quality-control concepts.

Results: Collating evidence from experimental reports and material characterization studies, textile-based nonwovens and composites constructed from recycled cotton/polyester blends and natural fibres demonstrate competitive sound absorption across mid-to-high frequencies and tunable thermal properties through density and porosity control. Agricultural fibres such as luffa show notable porosity and tortuosity characteristics that improve broadband acoustic absorption when structured as fibrous mats. Thermal performance benefits from low thermal conductivity inherent to porous fibrous structures, but moisture sensitivity and flammability remain obstacles that need mitigation.

Conclusions: Textile-based nonwoven composites are well-positioned to contribute to energy-efficient building envelopes and lightweight transport insulation systems when design practices emphasize porosity control, hybridization with other natural or mineral fillers, moisture management, and circular end-of-life planning. Policy-aligned industrial practices, integration with recycling infrastructures, and standards development will be central to scaling these solutions.

Implications: This paper offers researchers and practitioners a detailed descriptive methodological baseline and critical synthesis to design, test, and upscale sustainable textile-based insulation solutions that balance performance, life-cycle impacts, and circularity goals.